Work

Process envelope and void defect analysis in FSW of AA2024, AA5052 and AA7075 aluminium alloys

Year: 2026

Type: article

Abstract: This article investigates void defect formation in friction stir welding (FSW) of AA2024, AA5052 and AA7075. A total of 159 bead-on-plate welds were performed with real-time monitoring of temperature, force and spindle power. Travel speeds from 25 to 500 mm/min and tool rotation speeds from 300 to 1500 RPM were investigated. Process maps identified critical parameter ranges for different void defects. A new method was proposed to estimate torque from spindle power. Results show that high temperatures ( > 0.7 T solidus ) are necessary but not sufficient for defect-free welds. Torque thresholds can distinguish cavity from tunnel and groove defects, while power input below 1000 W (AA2024) or 1050 W(AA7075) is generally necessary and sufficient to avoid voids. These findings enable real-time defect monitoring and process optimisation in FSW.

Source: Science and Technology of Welding & Joining

DOI: 10.1177/13621718251413024

Authors: Xinrui Liu, Adrian P. Gerlich, Patricio F. Mendez

Institutions: University of Alberta, University of Waterloo

Language: English

Topic: Advanced Welding Techniques Analysis

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: hybrid

Estimated APC paid: $4,400

Funder: Natural Sciences and Engineering Research Council of Canada